Apparatus for the manufacture of continuous filament nonwoven web

ABSTRACT

The process and apparatus for manufacturing spunbonded nonwoven fabrics is disclosed, wherein continuous filaments of organic polymers are extruded, stretched to orient same, and then arranged in fabric form on a moving conveyor. The filaments are arranged or distributed on the moving conveyor by impact from a deflector surface, wherein at least that portion of the deflector surface wherein the filaments are at their maximum width is vibrated. The spunbonded nonwoven fabrics produced are more homogeneous than similar fabrics produced without vibrating the deflector surface. The fabrics are suitable for conventional uses of spunbonded nonwoven fabrics, such as apparel backing, padding and the like.

United States Patent 11 1 Porte 1 1 Dec.2, 1975 1 1 APPARATUS FOR THEMANUFACTURE OF CONTINUOUS FILAMENT NONWOVEN WEB [75] lnventor: PierrePorte, Lyon, France [73] Assignee: Rh'one-Poulenc-Textile.Paris,

France [22] Filed: Mar. 28, 1974 [21] Appl. No.: 455,810

Related US. Application Data [62] Division of Scr. No. 320,843. Jan. 4.1973. Pat. No.

[30] Foreign Application Priority Data Jan. 4. 1972 France 72.00264 [52]US. Cl. 156/433; 223/] SM; 156/148; 156/167; 156/180; 156/494 [51] Int.Cl. B6511 33/02 [58] Field of Search 156/433, 494. 167. 180. 156/148;253/1 SM [56] References Cited UNITED STATES PATENTS 3,148,101 9/1964Allman et al. 156/167 3.236.616 2/1966 Staleso et a1 156/167 3.439.0854/1969 Hartmann 156/167 3.593.074 7/1971 lsakoff 156/167 3.704.19111/1972 Burcsh ct a1 156/148 Primary E.\'aminer-Edward G. WhitbyAttorney. Agent. or FirmCushman. Darby & Cushman [57] ABSTRACT Theprocess and apparatus for manufacturing spunbonded nonwoven fabrics isdisclosed. wherein continuous filaments of organic polymers areextruded. stretched to orient same. and then arranged in fabric form ona moving conveyor. The filaments are arranged or distributed on themoving conveyor by impact from a deflector surface, wherein at leastthat portion of the deflector surface wherein the filaments are at theirmaximum width is vibrated.

The spunbonded nonwoven fabrics produced are more homogeneous thansimilar fabrics produced without vibrating the deflector surface. Thefabrics are suitable for conventional uses of spunbonded nonwovenfabrics. such as apparel backing. padding and the like.

10 Claims, 4 Drawing Figures U.S. Patent Dec. 2, 1975 3,923,587

APPARATUS FOR THE MANUFACTURE OF CONTINUOUS FILAMENT NONWOVEN WEB Thisis a division, of application Ser. No. 320,843 filed Jan. 4, 1973 nowUS. Pat. No. 3,853,651.

BACKGROUND OF THE INVENTION Spunbonded nonwoven textile fabrics arenonwoven textile fabrics substantially made of continuous filamentsgenerally randomly disposed throughout the fabric.

The manufacture of spunbonded nonwoven textile fabrics generallyconsists of extruding through a spinneret a melted, or even dissolved,fiber-forming organic polymer. Depending upon the nature of theparticular polymer involved, the extruded filaments are generally nextoriented by stretching the extruded fiber bundle, generally bypneumatically stretching the filaments with one or several compressedair jets. Then, the filament bundle is deposited in a predeterminedmanner on a moving conveyor, with the speed and the method of feedingthe conveyor being regulated to control the desired thickness and widthof the nonwoven fabric, and also to increase the regularity orhomogeneous nature, thereof. After being deposited on the movingconveyor, the spunbonded fabric is often subjected to a calendaringstep, generally a relatively light calendaring step, preferably with theapplication of heat, to increase the cohesiveness of the final product.Generally this calendaring step causes some of the basic filaments to bebound to one another, markedly increasing the unity of the nonwovenfabric product.

As mentioned above, after the textile filaments have been extruded andstretched, the filaments are deposited on a moving receiving conveyor.The distribution of the filaments on the conveyor is normallyaccomplished with the use of deflector surfaces. The bundle of filamentsis directed upon and impinges the deflector surface at a certain angleand then, after impingement, moves in a tangential direction along andoff of the deflector surface. The deflector surfaces are in the form offlat or curved surfaces, preferably curved surfaces of revolution, whichcan be either concave or convex in relation to the direction of travelof the filaments.

It is known to utilize fixed, flat deflectors to produce relativelyregular textile fabrics, and this involves a relatively simple design.However, the width of the distributed fibers, as well as their strength,is often less than desired. The art prefers to use deflectors whichproduce a greater filament spread, as such use permits a decrease in thenumber of filament extrusion or spinning positions for a given width offinal fabric produced. To achieve a sufficient filament spread, the arthas used deflectors with complex surfaces, or movable deflectors, eitherflat or curved, which lead to greater filament spreads. However, thesemoveable deflectors are mechanically relatively complicated, expensive,difficult to precisely regulate, and relatively untrustworthy.

From the above, it will be appreciated that until now it has not beenpossible to obtain in a simple manner elementary spunbonded fabricswhich are strong, regular, and have the desired width.

US. Pat. No. 2,736,676 discloses a process for producing sheets or matsmade of strands, yarns, or slivers of various materials, especiallyglass strands. The glass strands are extruded, stretched, and thenimpinged on a deflector surface. The patent discloses that the deflectorsurface may be either flat or curved, and may be fixed or moveable. Theangle of impingement is disclosed as being between 0 and The patentdiscloses, with relation to FIG. 7 thereof, the use of two air jets,mounted on opposite sides of the point of impact, to laterally sweep thestrand from the deflector surface, by alternate operation. The patentalso discloses, with relation to FIGS. 8 and 9 thereof, the use of anair jet operating behind the point ofimpact to aid in throwing thedeflected strand a further distance from the point of impact to areceiving conveyor. Another effect of the use of these air jets is tospiral the filaments, so that the filaments are deposited on thereceiving conveyor in the form of loops. The process of this patent.however. still suffers the defects of prior processes mentioned above,namely inadequate width and poor homogeneity of the resulting product.

US. patent application Ser. No. 247,874 of Marchadier and Togny,assigned to the common assignee, filed Apr. 26, 1972, discloses the useof a fluid jet device operating upon the point of impact of thefilaments on the deflector surface from a location in front of the pointof impact in relation to the direction of the deflected filaments, andin the same plane as the axis ofthe filaments before and after impactwith the deflector surface.

SUMMARY OF THE INVENTION The process of the present invention involvesthe use of a vibrating deflector surface upon which the polymericfilament is impinged, to produce in a simple way a spunbonded nonwoventextile fabric having an improved spread or width and improvedhomogeneity. At least one bundle of filaments is extruded and stretchedby conventional methods. Then the filaments are distributed upon amoving receiving conveyor by means of a deflector surface, with at leastthat portion of the deflector surface at the point where the filamentshave their maximum width being vibrated. Fluid jets may be associatedwith the deflector surface if desired.

DESCRIPTION OF THE INVENTION Spunbonded nonwoven textile fabrics aremanufactured by extruding filaments of a fiber-forming polymer,orienting the extruded filaments by stretching, and then distributingthe filaments on a receiving conveyor by impinging the filaments on asmooth deflector surface. The process of the present invention involvesvibrating at least that portion of the smooth deflector surface wherethe bundle of filaments has the maximum spread or width. This area ofthe deflector surface is that portion which is nearest the movingreceiving conveyor. The filaments may impact the smooth deflectorsurface on a fixed portion of the deflector surface or on a vibratingportion of the deflector surface. as long as the filaments are subjectedto the vibration step at the aforesaid point of maximum width on thevibrator surface.

Various types of filaments may be used in the present process ofmanufacturing spunbonded nonwoven tex tile fabrics. The filaments may bemade of fiber-forming inorganic polymers, such as glass, althoughpreferably the filaments are made of a fiber-forming organic polymer.Any of the conventional textile fiber-forming organic polymers may beused, such as cellulose acetate, nylon or other polyamide, rayon,acrylic, modacrylic and the like. However, the present process isparticularly useful in the production of polyester spun- 3 bondednonwoven fabrics. Preferably, the polyester is a polyalkyleneterephthalate. When the term polyalkylene tcrephthalate" is used in thepresent specification. it is to be understood to apply to polymericlinear terephthalate esters formed by reacting a glycol of the sericsHOlCH l oH wherein n is an integer of 2 to 10, inclusive, withterephthalic acid or a lower alkyl ester of terephthalic acid, whereinthe alkyl group contains 1 4 carbon atoms, such as, for example.dimethyl terephthalate. The preparation of polyalkylene terephthalatesis disclosed in US. Pat. No. 2,465,319 to Whinfield and Dickson, thedisclosure of which is hereby incorporated by reference. The most widelyused and commercially attractive polyalkylene terephthalate material ispolyethylene terephthalate, which is the most preferred polymer in thepractice of the process of the present invention. Polyethyleneterephthalate is generally pro duced by an ester interchange betweenethylene glycol and dimethyl terephthalate to form bis-Z-hydroxy ethylterephthalate monomer, which is polymerized under reduced pressure andelevated temperature to polyethylene terephthalate. The fiber-formingpolymers are extruded into continuous textile filaments, generally ofabout 4 to 70 dtex.

The filaments may be extruded at extrusion rates which are conventionalin the textile field. However, it is preferred that the impinging fibersbe travelling at a speed of about 50 to 130 meters per second at thetime of impact with the deflector surface, and the extrusion rate may beaccordingly adjusted.

After extrusion, the filaments are generally stretched by an amountsufficient to orient the polymer molecules in the filament. Generally,the stretching will be within the range of about 200 to about 400%,based on the unstretched length of the filaments. Preferably, thefilaments are stretched by pneumatic means, but other means may beutilized, such as those disclosed in the aforesaid U.S. Pat. No.2,736,676, the disclosure of which is hereby incorporated by reference.

After being stretched, the filaments are directed at the deflectorsurface, and impinged on the surface, generally at the aforesaid speedof about 50 to 130 meters per second. While the angle of impingement maybe from slightly more than up to slightly less than 90, e.g. 1 to 89, itis preferred that the angle of impingement be from to 80, morepreferably to 60.

The deflector surface may be flat or curved, and if a curved surface isused, it is preferred that the curved surface be a surface ofrevolution. The curved surface may be either concave or convex, and maybe either stationary or moveable, as known to the art. Any of the knowndeflectors, such as those disclosed in the aforesaid U.S. Pat. No.2,736,676, may be used in the practice of this invention. It isimportant that the deflector present a smooth surface in order toprevent any restraint of the filaments and to prevent any filamentimpingement that might disturb the regularity of the deflectedfilaments. In normal operation, the nature of the deflector material hasno significant influence upon the formation of the spunbonded nonwovenfabric. However, it is clear that the material of which the deflectorsurface is made must have sufficient strength and resistance to abrasionso that the impingement ofthe filaments and the fluid jet will notdeterioriate the surface. Among suitable materials for the deflectorsur- 4- face may be mentioned soft steel, bronze, glass. ceramics, andthe like.

A fluid jet may be directed to the point of impact of the filaments withthe deflector surface. This fluid jet is conveniently formed by passingthe fluid, preferably a gas, and most preferably compressed air, underpressure, through a nozzle. The use of a fluid jet generally allowsgreater filament speeds to be obtained. In the case of compressed air,the air is suitably under a pressure of between about 1 to about 4 bars.The nozzle preferably has a circular crosssection of a diameter of 0.5to 5 millimeters, preferably 1 3 millimeters, although the nozzlecross-section can be of shapes other than circular. For instance, thenozzle may be in the form of a rectangular or eliptical slot, having itsmajor axis in the vertical plane defined by the axis of the impingingfilaments and the average axis of the deflected filaments. In any event,the nozzle cross-sectional area is preferably no larger or smaller thanthat of the circular nozzle mentioned above. It should be understoodthat the fluid pressure and nozzle areas mentioned above are notlimiting, but are decidely preferred, as it has been observed that lowerpressures or greater cross-sectional areas produces an insufficientdeflected filament spread, whereas higher pressures or smallercross-sectional areas generally adversely affect the homogeneous natureof the resultant nonwoven fabric product.

Particularly good results are obtained when the fluid jet acts in amanner which does not destroy the symmetry of the impacting bundle offilaments. This is accomplished by having the fluid jet substantially inthe vertical plane which contains the axis of the impacting filamentsand the average axis of the deflected filaments. The deflected filamentswill be on diverging paths, so that some of the deflected filaments willbe in a different vertical plane than other of the deflected filaments.Therefore, an average axis must be considered. In addition, thedeflected filaments may be subjected to a sweeping action, e.g. such asthat caused by movement of the deflector surface, and this also must beconsidered when determining the average axis of the deflected filaments.The velocity of the fluid jet should not be so great as to destroy thefilament bundle symmetry.

Preferably, but not necessarily, the fluid jet is a gas, which generallyis chemically inert with respect to the filament. It is, however,possible to use a gas or other fluid which does react with thefilaments, if such action is desired. Compressed air is convenientlyused as the inert gas, as being efficient and economical, but othergases may also be used, such as nitrogen, carbon dioxide, helium and thelike, and liquids, such as water, while not preferred, can be used aswell.

The distance from the end of the fluid jet nozzle to the point of impactof the filaments on the deflector surface will vary according to thetype of fluid, fluid pressure, nozzle size, diameter and number offilaments, and desired width of the fabric product. Generally, thenozzle will be located a few centimeters from the point of impact, butthis distance can be as great as a few deeimeters. Generally, thedistance will be no greater than 5 decimeters and no less than about 2centimeters, but preferably the distance is between 2 and 5 centimeters.

The vibrating deflector results in a better entanglement of thefilaments and improved distribution of the filaments in the fabric, withthe result that more regular, homogeneous fabric can be produced. Thedeflector, as mentioned above. may be either fixed or moveable, and maybe of a plane form or curved. The deflector can be made of any rigidmaterial, including stratified materials, which have a coefficient ofsurface friction compatible with the extruded material. Generally,metals are preferred materials for the vibrating deflector. If desired,the deflector surface may be coated with a film of an elastomer or thelike, or ofa product having a paper-like characteristic.

The deflector surface, or portion thereof, may be vibrated or actuatedby various known means, including mechanical, electromagnetic, magnetic,pneumatic, or by resonance. The vibration can also be accomplished bythe incident fluid directed upon the point of impact of the filamentswith the deflector surface, if such fluid is used.

At least a portion of the deflector surface will be vibrated at afrequency of about 1.67 1000 vibrations per second, preferably about 850 vibrations per second. The amplitude of the vibrations variesaccording to the dimensions of the vibrating deflector surface, but willgenerally be within the range of about 5 30% of the vibrating deflectorsurface portion length. That is, for a vibrating part which is 100 mm inlength, the amplitude of the vibrations are generally within the rangeof 5 30 mm at the deflector extremity.

Obviously, several units each comprising a deflector surface andassociated vibrating means can be mounted side by side to treat aplurality of filament bundles, with each group of filaments so treatedon each unit forming a portion of the final fabric. This approachpermits the ready production of extremely wide spunbonded nonwovenfabrics. Using this approach, care must be taken to avoid thedisturbance of one deflected group of filaments by another group at thetime of depositing the filaments on the conveyor. It is preferred todisplace the deflected group of filaments so that they contact theconveyor in a stepwise manner. This is readily done by displacing thedeflectors so that the planes of the deflected filaments leaving thedeflector surface are parallel, and the points of impact are alignedalong a straight line which is parallel to the plane of the receivingconveyor. This insures that the distance travelled by each group offilaments between the point of impact and the conveyor surface is thesame.

After the filaments are deposited on the receiving conveyor, in thegeneral form of the spunbonded nonwoven textile fabric, the depositedfilaments are sub jected to conventional treatments to improve thecohesiveness of the nonwoven fabric product. Generally the use ofneedlepunching or a relatively light calendaring step is preferred,although other approaches, such as use of an adhesive, can also beutilized. For polyalkylene terephthalate filaments, a calendaring stepusing a nip pressure of 50 kilograms per centimeter and a temperature of140 250C is preferred. For needlepunching, the fabric is preferablyneedlepunched at a penetration density of about 5 500 penetrations persquare centimeter, although it will be appreciated that even greaterpenetration densities may be used if desired. Preferably, thepenetration density will be in the range of 20 100 penetrations persquare centimeter.

The weight of the spunbonded nonwoven fabric produced, for a givenfabric width, can be controlled by varying the speed of the receivingconveyor and/or the extrusion rate of the filaments. In the case ofpolyethylene terephthalate, the fabric weight will generally be in 6 therange of 10 to 200Og/m preferably 10 to 500 grams per square meter, mostpreferably to grams per square meter.

The distance between the point of impact of the filament bundle on thedeflector surface and the receiving conveyor can be convenientlyregulated by shifting the conveyor. The weight of the resulting fabriccan be varied by changing the speed of the receiving conveyor and/or bychanging the rate of filament extrusion. The use of the vibratingdeflector allows lightweight fabrics to be produced having a high degreeof regularity. As mentioned, if very wide fabrics are desired, severalunits, each consisting of at least one drawplate, a stretching nozzle,and a vibrating deflector, can be mounted in a side-by-siderelationship, with each bundle of filaments thus forming a portion ofthe final fabric.

Because of the equipment simplicity and adaptability, the vibratingdeflector can be used on any conventional apparatus for manufacturingspunbonded nonwoven fabrics. The spunbondcd fabric may be either of anatural color or may be colored in the bulk. The fabric may be used assuch or printed, impregnated with pulverized or liquid adhesives orother products or needlepunched in one or several layers. The spunbondedfabric may be made of heat-bondable material or of material which is notheat-bondable. The heat bonds may be developed on appropriate filamentsby thermal treatment. The spunbonded nonwoven fabric produced by theapparatus and process of the present invention may be used inapplication where prior spunbonded nonwoven textile fabrics have beenused. such as apparel backing, padding for garments and furniture andthe like, for filters, sound and thermal installation, and in housingand in public works and buildings.

DESCRIPTION OF THE DRAWINGS The invention will be more readilyunderstood with reference to the accompanying drawings, wherein:

FIG. 1 represents a schematic side view of the pro cess of the presentinvention,

FIG. 2 represents a front view of a portion of the process depicted inFIG. 1,

FIG. 3 represents another embodiment of the vibrating deflector surface,and

FIG. 4 represents yet another embodiment of the vibrating deflectorsurface.

In FIGS. 1 and 2, filaments l are extruded through a spinneret 2 by aconventional extruder (not shown) and passed through a stretchingcompressed air nozzle 3, wherein the filaments are stretched to orientsame. The filaments discharged from the stretching compressed air nozzle3 impact upon the fixed deflector surface portion 4. A compressed airjet 9 formed by compressed air nozzle 8 is directed at the point ofimpact of the filaments l with the fixed deflector surface portion 4,and this compressed air jet 9 assists in the spreading of the bundle offilaments. The filaments passing down the deflector surface pass overvibrating deflector surface portion 5, wherein the vibration is obtainedby means of a cam 7, having a generally square configuration, driven bymotor 6. The filament bundle continues to open under the influence ofthe vibrations, with the filament bundle opening increased and thefilaments somewhat undulated by the action of vibrating surface 5. Thus,the plane filament bundle is transformed into a three-dimensionalfilament bundle 10 which is received in the form of spunbonded nonwoven7 fabric 11 on receiving conveyor 12. The receiving conveyor 12 has alower speed than the filament bundle 10. The conveyor 12 may besubjected to a transversal displacement movement, as can the otherequipment mentioned above.

FIG. 3 represents an alternative apparatus for vibrating the vibratingdeflector surface portion. Vibrating deflector surface portion 32 abutsfixed deflecting surface portion 31. The vibrating portion 32 is made offerromagnetic material and is vibrated by means of electromagnetic meanscomprising an electromagnetic bar 33, connected to an electricalcircuit.

FIG. 4 represents yet another alternative embodiment for vibrating thevibrating deflector surface portion. The vibrating portion 42 abutsfixed vibrator surface portion 41. Vibrating portion 42 is vibrated bymeans of bar 43 actuated by solenoid 44.

EXAMPLES OF THE lNVENTlON The invention will be understood more readilyby ref erence to the following examples; however, these examples areintended to illustrate the invention and are not to be construed tolimit the scope of the invention. In the following examples. theresistance to rupture was obtained by the procedure of AFNOR (307.001 ofAug. 1944. The extension values were obtained according to theprocedures of AFNOR (307.001 of Aug. 1944 and the tear strengths weredetermined according to the procedure of AFNOR (307.001 of Aug. 1944.

EXAMPLE 1 Two parallel bundles of filaments, each bundle having 70filaments of 8.8 dtex, of polyethylene terephthalate were extrudedthrough two spinnerets at a rate of kg/hour per spinneret. The distancebetween the axis of the two bundles of filaments discharged from the twospinnerets was 480 mm.

Each extruded bundle of filaments was then stretched 350% of itsoriginal length during passage through a compressed air nozzle and thenpassed through an apparatus formed by a rectilinear tube and a platelocated at the extremity of the tube. The plate was a plane inclinedsurface cutting across the major axis of the tube at an angle of 10. Thefilaments discharged from the surface of the plate were received on afixed vibrating deflector.

The fixed vibrating deflector was a plane deflector having a fixed glassportion which was l50 mm in length and 100 mm in width. Between thefixed glass portion and the receiving apron of the moving conveyor.described hereinafter, and adjacent the fixed deflector surface. was avibrating plane deflector portion of polished bluish steel which was 155mm in length and 90 mm in width (the length of the vibrating deflectorportion was parallel to the axis of the moving conveyor). Theinclination of the deflector surface (the two portions thereof werelocated in the same plane) in relation to the rectilinear tube was 125and in relation to the moving conveyor receiving apron was 80. Thevibrating deflector portion was actuated. or vibrated. by a motordriving a square cam having sides 57 mm long. The vibrating deflectorportion was vibrated at 2000 vibrations per minute, corresponding to avibrating frequency of 33.3 vibrations per second. The extremity of thevibrating portion (furtherest removed from the fixed portion) had anamplitude of $10 mm. The opposite extremity of the vibrating portion(closest Conveyor Speed m/min 9.6 6.7 3.35 2.20 Web Weight g/m l 00 100200 300 The web was then needle punched on one face with needles 9 cm inlength, each needle having 3 ridges with 3 sharp edges, each disposed ina helixical fashion. The needles penetrated 15 mm, and the needlepunching density was 50 punches per square centimeter.

The needle punched web, having a weight of 200 g/m had the followingmechanical characteristics:

Resistance to rupture Extension Tear Strength Machine direction (alonglength of web) Crossmachine direction (along width of web) 34 kg 11.7 k

This example was repeated, except the vibrator was not used. Theresulting web, again of a weight of 200 g/m had the followingcharacteristics:

Resistance to rupture Extension Tear Strength Machine direction (alonglength of web) Crossmachine direction (along width of web) 15 kg 3371 5kg It will be noted that a more isotropic web was obtained by use of thevibrating deflector according to the present invention.

The web obtained with the vibrating deflector could be used as coatingbacking, padding underfelt, and the like.

EXAMPLE 2 Example 1 was repeated. with the distance between the twoextruded bundles of filaments being 720 mm. The fixed deflector wasreplaced by a plane deflector having a cyclically oscillating motionaround a vertical axis parallel to the impinging filament bundle,oscillated at the rate of 60 round trips per minute about its axis withthe total travel spanning an arc of 22.

The vibrating deflector was composed of a glass nonvibrating deflectorportion and a bluish steel vibrating deflector portion. The latterportion had a thickness of 0.2 mm. The dimensions of the fixed deflectorportion were 150 mm in length and 100 mm in width, whereas the vibratingdeflector portion was 150 mm in length and 90 mm in width. The length ofthe deflector on the average, or mid-point, position of oscillation wasparallel to the axis of the receiving apron of the moving conveyor. Thedeflector made an angle of 125 with the vertical and was located mm fromthe tube/plate apparatus. The distance from the lower edge of thedeflector to the receiving apron was 45 cm. The distance from the pointof impact of the filaments on the deflector to the receiving apron was690 mm, with the filaments impacting the deflector at the center of thefixed portion thereof.

The vibrating portion of the deflector was actuated by electromagneticmeans and had a vibration speed of 1000 vibrations per minute,corresponding to a vibration frequency of l6.6 cycles per second. Theextremity of the vibrating portion had an amplitude of i 12 The twobundles of deflected filaments were combined to produce a web of 1.4meters in weight, whose weight varied with the speed of the receivingapron conveyor similar to Example 1.

A web having a weight of 200 g/m was needlepunched as in Example 1,producing a needlepunched web having the following mechanicalcharacteristics: 1

Resistance to rupture Extension Machine direction (along length of web)kg 72% Cross-machine direction (along width of web) 37 kg 55% Resistanceto rupture Extension Machine direction (along length of web) 29 kg 64 7:Cross-machine direction (along width of web) 40 kg 59% The coefficientof irregularity of this second web was 9.8%.

It will be appreciated from the above that the web produced utilizingthe vibrating deflector surface was more isotropic and had improvedresistance to rupture in the machine direction. The resulting web wassuitable for use in manufacturing wall coatings.

EXAMPLE 3 A web having a weight of 120 g/m was made by extruding 6parallel bundles of polyethylene terephthalate fibers, each bundle beingformed of 60 filaments of 4.4dtex. Each bundle was extruded through aseparate spinneret at the rate of9.3 kilograms per hour per spin neret,and the centers of the spinnerets, were separated by a distance of 370mm.

The filaments were stretched 350% of their original length by acompressed air nozzle and then discharged upon a fixed deflectorassociated with a compressed air jet. The compressed air jet was appliedat the point of impact of the filaments on the deflector, at an angle of35 with the impinging filament bundle. The air jet was formed by passingcompressed air at a pressure of 3.5 bars through a nozzle having acircular port 3 mm in diameter, with the end of the nozzle located about30 mm in front of the point of impact. The deflector was made with aglass fixed deflector portion having a length of l50 mm and a width ofmm and a vibrating deflector portion (made of stratified glass andpolyester resin. with a glass surface) having a length of 150 mm and awidth of 90 mm. The extremity of the vibrating deflector had anamplitude of i 10 mm, and the vibrating portion was vibrated at afrequency of 16 cycles per second by electromagnetic means.

The filaments discharged from the vibrating deflector were passed to anincline apron at an angle of 45 and moving at a speed of 4 meters perminute, of a moving conveyor. The inclined apron was located 45 cm fromthe extremity of the vibrating deflector portion.

The resulting web was nccdlepunched similar to Example l, and then had awidth of 2l0 mm and a weight of g/m and the following characteristics:

This web had an irregularity coefficient of 5.5%.

When this example was repeated, but without the use of the vibrator, aweb of 120 g/m was obtained which had an irregularity coefficient of6.5% and the follow ing physical characteristics.

Resistance to rupture Extension Machine direction (along length of web)l8 kg 5071 Cross-machine direction (along width of web) 37 kg 42% Thus,the use of the vibrating deflector surface increases the regularity ofthe resulting web. The resulting spunbonded nonwoven fabric productcould be utilized in manufacturing light coating backing or interlining.

What is claimed is:

1. Apparatus for making spunbonded nonwoven fabrics. said apparatuscomprising means for producing a plurality of filaments of an organicpolymer. means for stretching said filaments to orient same. movingreceiving means. and deflector surface means associated with saidstretching means for distributing the stretched filaments on said movingreceiving means by impacting said filaments on said deflector surfacemeans. at least that portion of said deflector surface means wherein theplurality of filaments have their maximum width being vibrated in asubstantially vertical plane at a frequency of 1.67 1000 vibrations persecond at an amplitude of of the length of the deflector surface means.

2. Apparatus according to claim 1, wherein only a portion of saiddeflector surface means is vibrated.

3. Apparatus according to claim 1, wherein the entire deflector surfacemeans is vibrated.

4. Apparatus according to claim 1 including fluid jet means fordirecting a fluid jet at the point of impact of said filaments on saiddeflector surface means.

5. Apparatus according to claim 1 wherein said portion of said deflectorsurface means is vibrated at a frequency of 8 50 vibrations per second.

6. Apparatus according to claim 1, additionally including means toneedlepunch the filaments received on said moving receiving means.

7. Process according to claim 1, additionally including means tocalendar the filaments received on said moving receiving means.

8. Apparatus according to claim 1, wherein said deflector surface meansincludes a fixed portion of said deflector surface means. wherein thefilaments are impacted. and another portion of the deflector surfacemeans, wherein the filaments are vibrated.

9. In an apparatus for making spunbondcd nonwoven textile fabrics thatincludes means for producing a plurality offllamcnts of a fiber formingpolymer means for stretching said filaments to orient the same. movingreceiving means and deflector surface means associated with saidstretching means for distributing the stretched filaments on said movingreceiving means by impacting said filaments on said deflector surfacemeans, the improvement comprising a deflector surface means wherein atleast that portion of the deflector surface wherein the plurality offilaments have their maximum width is vibrated in a substantiallyvertical plane by vibrating means which induce a frequency of l.67 to1,000 vibrations per second at an amplitude of 5 to 30% of the length ofthe deflectors surface means.

10. Apparatus according to claim 9, wherein said deflector surface meansincludes a fixed portion of said deflector surface means, wherein thefilaments are impacted. and a vibrating portion of the deflector means,wherein the vibrating portion of the deflector surface means is locatedon the end of the deflector surface nearest the moving receiving means.

k l l l

1. APPARATUS FOR MAKING SPUNBONDED NONWOVEN FABRICS, SAID APPARATUSCOMPRISING MEANS FOR PRODUCING A PLURALITY OF FILAMENTS OF AN ORGANICPOLYMER, MEANS FOR STRETCHING SAID FILAMENTS TO ORIENT SAME, MOVINGRECEIVING MEANS, AND DEFLECTOR SURFACE MEANS ASSOCIATED WITH SAIDSTRETCHING MEANS FOR DISTRIBUTING THE STRETCHED FILAMENTS ON SAID MOVINGRECEIVING MEANS BY IMPACTING SAID FILAMENTS ON SAID DEFLECTOR SURFACEMEANS MEANS, AT LEAST THAT PORTION OF SAID DEFLECTOR SURFACE MEANSWHEREIN THE PLURALITY OF FILAMENTS HAVE THEIR MAXIMUM WIDTH BEINGVIBRATED IN A SUBSTANTIALLY VERTICAL PLANE AT A FREQUENCY OF 1.67 - 1000VIBRATIONS PER SECOND AT AN AMPLITUDE OF 530% OF THE LENGTH OF THEDEFLECTOR SURFACE MEANS.
 2. Apparatus according to claim 1, wherein onlya portion of said deflector surface means is vibrated.
 3. Apparatusaccording to claim 1, wherein the entire deflector surface means isvibrated.
 4. Apparatus according to claim 1 including fluid jet meansfor directing a fluid jet at the point of impact of said filaments onsaid deflector surface means.
 5. Apparatus according to claim 1 whereinsaid portion of said deflector surface means is vibrated at a frequencyof 8 - 50 vibrations per second.
 6. Apparatus according to claim 1,additionally including means to needlepunch the filaments received onsaid moving receiving means.
 7. Process according to claim 1,additionally including means to calendar the filaments received on saidmoving receiving means.
 8. Apparatus according to claim 1, wherein saiddeflector surface means includes a fixed portion of said deflectorsurface means, wherein the filaments are impacted, and another portionof the deflector surface means, wherein the filaments are vibrated. 9.In an apparatus for making spunbonded nonwoven textile fabrics thatincludes means for producing a plurality of filaments of a fiber formingpolymer, means for stretching said filaments to orient the same, movingreceiving means and deflector surface means associated with saidstretching means for distributing the stretched filaments on said movingreceiving means by impacting said filaments on said deflector surfacemeans, the improvement comprising a deflector surface means wherein atleast that portion of the deflector surface wherein the plurality offilaments have their maximum width is vibrated in a substantiallyvertical plane by vibrating means which induce a frequency of 1.67 to1,000 vibrations per second at an amplitude of 5 to 30% of the length ofthe deflector''s surface means.
 10. Apparatus according to claim 9,wherein said deflector surface means includes a fixed portion of saiddeflector surface means, wherein the filaments are impacted, and avibrating portion of the deflector means, wherein the vibrating portionof the deflector surface means is located on the end of the deflectorsurface nearest the moving receiving means.